Abrasion resistant conformal beaded-matrix for use in safety garments

ABSTRACT

An abrasion resistant garment and method of producing same. A garment that is highly ventilated while providing abrasion protection for a wearer during a slide, as for instance that may occur during a fall from a motorcycle. A material is produced wherein abrasion-resistant, low sliding friction, beads are held within a matrix of high-tensile strength, abrasion-resistant, cords. The beaded matrix within the garment can be augmented with layers to form a lining and exterior layers to enhance visibility. The force of a sliding rider is retained over the beaded matrix, away from the road surface. Under abrasive sliding friction, the beads additionally rotate to an extent which tightens the cord matrix and thereby helps constrain the skin surface of the wearer from making contact with the roadway surface.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a Continuation-In-Part claiming priority fromU.S. application Ser. No. 09/718,735 filed Nov. 22, 2000 by the sametitle.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not Applicable

REFERENCE TO A MICROFICHE APPENDIX

[0003] Not Applicable

BACKGROUND OF THE INVENTION

[0004] 1. Field of the Invention

[0005] The present invention relates generally to the manufacture ofabrasion-resistant safety garments, and more particularly to aconformal-beaded matrix which may be incorporated within garments toprotect the wearer from abrasion.

[0006] 2. Background of the Description

[0007] Various forms of safety garments have been created for use insports such as motorcycling, bicycling, skating, skateboarding. Many ofthese garments incorporate impact absorbing areas and abrasion resistantmaterials which improve wearer safety. The protection offered by thesesafety garments fall into two main categories: impact protection andabrasion protection. Padded areas, often within resilient cups that maybe constructed of materials such as Temperfoam™, are often sewn intogarments over impact-sensitive areas, such as over the knees, elbows,shoulders, ankles, and even over the spine. These impact absorbingsections are often referred to as “body armor”. Densely woven materials,generally provided in layers, are used within these safety garments forpreventing abrasion over the remaining fleshy areas of the user.Traditionally one of the best materials for these safety garments hasbeen thick leather (i.e. over 1.5 mm), as it provides abrasionresistance many times greater than traditional cloth materials. Newermaterials such as ballistic nylon, Cordura™, Gortex™, Kevlar™, alongwith armor sections, are being incorporated within otherwisetraditionally constructed cloth garments in order to increase theirabrasion resistance. These garments rely on the use of layers of densedurable abrasion resistant cloth materials to protect the wearer.

[0008] Often minor abrasions are referred to as “road rash” wherein aslowly moving body contacts a roadway surface at a speed of under 15-20mph. However in sports such as motorcycle riding, a fall at evenmoderate speed on a roadway surface can result in severe abrasions;whereby not only the skin is abraded away, but significant amounts offlesh, muscle, and bone can be similarly removed. Even moderate abrasionwounds are painful and slow healing. Severe abrasion wounds can resultin a significant blood loss, an infection hazard, a likelihood ofpermanent disfigurement, and even death.

[0009] Everyday clothing provides insignificant levels of abrasionresistance, such as to a motorcycle rider failing on a roadway. InAustralia in, 1982, the Royal Brisbane Hospital Burn Unit completed a13½ year study of motorcycle burn injuries wherein 29% of the burn unitvictims were road abrasion burns with 46% experiencing the burns to bothupper and lower extremities. Of these the median hospital stay was 8days, but ranged up to 186 days. It was concluded that proper safetyclothing would have prevented all of these road abrasion burns. Similarstudies have been conducted in England, Germany and other countries withsimilar results.

[0010] Insurance industry and government committees have been lookingclosely into regulations directed at safety garments. At this timeGermany is considering compulsory clothing standards which requiremotorcycle riders to wear certified safety garments, while the BritishStandards Institute of the British government is drafting standards forprotective clothing for motorcycle riders.

[0011] As can be seen, therefore, abrasion-resistant protective clothingshould be worn when one is involved an any high speed activity where oneis otherwise unprotected from abrasion as a result of a fall. However,the use of protective clothing is often ignored, even though equipmentcurrently exists which can largely protect riders from impact andabrasion injuries. Part of the lack of acceptance of current safetygarments may lie in the numerous drawbacks that are inherent in thedesigns which limit their proper habitual use.

[0012] There are generally two principle forms of safety garmentsavailable for sports such as motorcycle riding; the first category isleathers, while the second is cloth type garments. Thick leatherprovides a good measure of protection and is favored by the majority ofcompetitive riders. Its thickness and durability often requires thatonly a single layer is required to prevent abrasion. However the leatherdoes not stretch nor does it allow air-flow to reach the wearer.Protection in the many current cloth-type safety garments is provided bymeans similar to those used within ballistic protection gear, such as socalled “bullet proof vests”; wherein a tightly closed material structureis created through which no objects can incur. Layers of densely wovenKevlar™ and carbon fibers have replaced steel chain-mail typeconstruction in these protection suits. Within an abrasion resistantgarment, numerous layers of material are utilized to provide redundancyas a layer wears through during a fall, and to provide thermalinsulation. To further enhance protection against abrasion, moreballistic armor techniques have been considered, such as covering theexterior of the garment with closely spaced platelets. Within ballisticprotection suits the platelets are intended to prevent ballisticincursion, but in this case have been considered to prevent roadwayincursion. However, it will be appreciated that such approaches lead tothe creation of a heavy garment that is substantially covered withanti-ballistic material. Opening up platelet spacing then leads not onlyto a garment that tears on impact, but one in which the friction forcesrotate platelets, platelet halves, or platelet fragments, against theskin of the wearer inflicting additional injury. In general, abrasionresistant clothing follows the teachings of ballistic protection toprovide abrasion protection.

[0013] Unfortunately both the leather and cloth designs, whenpromulgated as abrasion safety garments, restrict air-flow andconsequently when worn in warm to hot weather are at best uncomfortable,and may in fact be unwearable, due to the high risk of hyperthermia.Thick garments such as these allow insignificant amounts of air to flowand thereby pose a dangerous hyperthermia risk as body temperatures cansoar. It is not surprising that a large percentage of safety-consciousriders don't ride when it gets warm out, . . . while others ridedangerous underprotected with street clothing. Clothing manufacturershave worked to provide various forms of venting for conventional safetygarments, however, venting is unable to compensate for the bulk oflayers of tightly woven material surrounding the wearer, and vents areof only minor aid when the wearer is stationary. To fully appreciate thesituation, it should also be remembered that in the case of a motorcyclerider, the rider is seated above an engine operating at hightemperature, the heat from which rises to envelope the rider.

[0014] Accordingly there is a need for abrasion resistant safetygarments that can be constructed to minimally restrict ventilation ofthe wearer. The abrasion resistant conformal beaded-matrix in accordancewith the present invention satisfies that need, as well as others, andovercomes deficiencies in previously known techniques.

BRIEF SUMMARY OF THE INVENTION

[0015] The present invention is an abrasion resistant garment and methodof garment construction that employs round beads held within asubstantially fixed two-dimensional open matrix of abrasion-resistantcords. Abrasion resistant beads with low levels of abrasive friction areattached within a crossing matrix of abrasion resistant cords.Constructed within a garment, the bead matrix allows a high degree ofventilation as it covers only a small percentage of skin surface (lessthan 50%), yet it can provide high levels of abrasion resistance toenhance the safety of sports such as motorcycle riding. It is preferredthat the ratio of bead diameter to spacing between adjacent beads is inthe range of approximately 1:1.5 to 1:8 (at 1:1 beads are adjacent oneanother). Most preferably with the embodiments described the ratio is inthe range of ratios of 1:2 to 1:4.

[0016] Within the current invention it has been recognized that abrasionresistance is not an analogous problem to that of ballistic protection.Presently, abrasion resistant garments solve the abrasion problem at amicro-level wherein incursion through the fabric is consideredthroughout the span of fabric. Therefore, the fabric must be of asubstantially uniform nature wherein no portions of the skin are to besubject to surfacial contact, being held apart from the road surface bya series of layers. It should be noted that these garments modeled onballistic principles do provide a level of ballistic (puncture)resistance, however, puncture-type injuries are not a primary source ofinjury during the majority of incidents. The current invention haseschewed the approach taken in ballistic protection garments and adopteda macro-level approach to the reduction of abrasion, whereby the pliableskin is treated as a integral surface as opposed to a collection ofsingularities. Within the invention, the skin of the wearer is held offof the pavement surface by abrasion-resistive beads periodically placedwithin an open matrix. Air flowing between the skin and surface insulatethe skin of the wearer from the abrasive surface. The abrasion betweenthe garment and the road surface takes place on the exterior ofprotruding beads while a large percentage of the skin is not covered bybead, yet is still protected by being retained within the matrix ofsupporting cords which span between the beads to thereby support thefleshy areas.

[0017] The following is an example that may aid visualization of thisforce distribution concept. Many people have watched in amazement aseastern mystics lie down on a bed of sharp nails and then rise againunscathed. These nails are sharp, and quite obviously any one of thesenails can penetrate the skin. However when the force of the body isdistributed across a number of these projections the force at eachprojection is insufficient to cause incursion of the skin surface by anyone nail. The person laying down does not need a bullet proof vest(micro-level concept) to prevent a nail from injuring them, they onlyneed to distribute the forces being applied (macro-level concept). Themethod according to the invention isolates abrasive forces at a seriesof bead contact points between the wearer and the roadway surface undersliding contact. In similar manner to the “bed of nails”, the forceacross the beaded matrix is thereby distributed. Unlike the bed ofnails, the wearer need not be careful of the rate at which the pressureis applied over the matrix, as the shape of each bead supportsincreasing loads the further it is depressed against the skin.

[0018] Each bead within the cord matrix is formed of a material whichprovides a low sliding resistance when contacting the road surface.These beads extending from the skin's surface bear the majority of thepressure from the rider. The conformal matrix is preferably constructedwith integral elastic within the cords of the matrix which retain thebeads near the skin surface, and which are capable of only limitedstretch under frictional load. An important safety factor within thematerial occurs under abrasive friction, whereupon the beads rotate totighten the attached matrix of cords to suspend the skin above theroadway surface between separated bead “pillars”. The beads areconfigured with limited attachment points, preferably four to six, whichretain them within the cord matrix while facilitating bead rotation. Thebeads have a substantially round surface in either one or twodimensions, and may rotate under urging such that side areas of the beadare exposed to the abrading surface. Preferably the beads are configuredas either spheres, or oval cylinders. The beads are therefore providedwith limited rotation, while they simultaneously take up the slack inthe cord matrix to properly retain and suspend the fleshy portions ofthe wearers skin riding above the beads.

[0019] In constructing a safety garment, it is preferably that theconformal beaded matrix be interrupted over the boney areas such asknees, shoulders, elbows, ankles, and spine to incorporate shockabsorbing structures, such as body armor sections of conventionalconstruction. It will be appreciated that although the beaded matrixprovides a high degree of abrasion protection while providing forair-flow, it provides very limited impact resistance. Although thebeaded matrix could be created as a single layer garment, it ispreferable that the beaded matrix be sandwiched between layers of thinopen-weave breathable cloth to improve appearance and for theincorporation of reflective material. The beaded matrix can beincorporated in garments constructed for any season of use depending onthe number and composition of the layers employed.

[0020] This method of providing abrasion safety departs from that ofprior garments in a number of respects. The open nature of the materialallows for very high levels of ventilation to be provided in a garmentwithout compromising safety from road abrasion. Garments producedtherefrom can be worn comfortably on even the hottest of days. Thepresent invention should have lower weight, increased airflow, and addedsafety when compared with conventional safety garments modeled afterballistic suits, or ballistic suits which consider the use of exteriorplatelets. Expanding the distance between the tiny plates attached overa conventional ballistic style safety garment to lighten the suit andprovide for airflow does not yield similar results as the presentinvention and may pose a safety risk. In an abrasive sliding situationthe edges of these plates catch the ground and rotate, this increasesgarment tearing while the opposing exposed edges of the plate are driveninto the wearer's flesh. Such a plate can easily be driven into anear-surface bone, such as a shin-bone, to cause a fracture. Providingspace between surface platelets, therefore, allows the edges to becomevulnerable to catching the ground. As an edge catches, the clothsurrounding it is in contact with the surface of the ground, caughtbetween the hard edge of the small plate and the hard road surface, suchthat the two in concert can grind through even abrasive resistant cloth.In addition the conventional construction of platelets have employedmetals or ceramics, which although durable, create high levels ofinterface friction between the garment and the roadway surface. The highdegree of friction causes high rotational torque on the sliding rider'sbody, thus increasing the extent of tumbling related injuries.

[0021] Within the beaded matrix of the invention, each bead retains around portion against the skin and a similar portion which is in contactwith the ground during a slide, there is no transition region, such asthe edge of a plate, during rotation of the bead element. It will beappreciated that the beads retained in the matrix may be of differingsizes in accord with the level of abrasive forces which may exist overthat area. For example, the skin surfaces of the inner thighs, betweenthe legs, are subject to far less abrasive risk than the anteriorportions near the hips. In some areas, such as the crotch or under thearms, the inclusion of beads within the matrix may be forgonealtogether. The rounded outer surface areas of each bead slides on thepavement surface easily without catching, and the inner surface areas ofeach bead make smooth contact with the wearers skin, applying smoothpressure gradients around the contact points of the beads, withoutprojecting edge regions into the skin or bone of the wearer. The softabrasion resistant beads, therefore, can partially rotate whilemaintaining a smoothly contoured exterior which is not prone to catchingthe surface of the road, and a smoothly contoured interior which willnot lacerate the rider. In addition, the rotation of a section of beadsenhances the safety of the garment as it causes the underlying matrix totighten up to hold the skin away from the road surface more effectively.The use of a conventional cloth material to retain the beads is notpreferred as the material then divides the bead into a lower and upperhalf and creates a transition region about the annular periphery wherethe cloth exits the bead. A conventional cloth material substantiallyinhibits bead rotation that provides the increased skin retentionforces, while the continuous span of cloth itself then becomes subjectto tearing. In contrast, the cord material of the matrix forms a veryopen structure, which allows each cord within the matrix to beconfigured with even large diameter cords, for instance {fraction(1/16)} to ⅛ inch, without significantly reducing airflow andflexibility, or unduly increasing cost. The large diameter of the cordmaterial can be produced with a very high resistance to abrasivewear-through. Also the beads, being of a soft material, do not act inconcert with the road surface to abrade the surrounding matrix. Movingagainst a surface of skin under compressive oscillating friction, thebeads should also induce lower levels of friction heating against theskin surface when compared to cloth.

[0022] An object of the invention is to provide abrasion-resistantgarments that can be constructed to provide improved ventilation.

[0023] Another object of the invention is to provide a material for theabrasion-resistant garment in which only a small surface of the wearersskin need be covered with the closed portions of material comprising thegarment.

[0024] Another object of the invention is to create a method ofproviding abrasion resistance within a garment that may additionallyemploy protective armor sections over boney area such as the knees,elbows, shoulders, ankles, and spine.

[0025] Another object of the invention is to provide abrasion-resistantgarments that can be worn with or without exterior layers for retainingwarmth.

[0026] Another object of the invention is to provide abrasion-resistantgarments that do not impose high rotational torque forces on fallenriders which can lead to additional injury.

[0027] Another object of the invention is to provide abrasion-resistantgarments wherein the frictional forces on the exterior beads during aslide tighten up the garment to restrict contact of integument with thepavement surface.

[0028] Another object of the invention is to provide a method ofobtaining abrasion resistance that does not rely on the use of acontinuous span of material coverage.

[0029] Another object of the invention is to allow for the creation ofabrasion-resistant garments which may be easily manufactured at lowcost.

[0030] Further objects and advantages of the invention will be broughtout in the following portions of the specification, wherein the detaileddescription is for the purpose of fully disclosing preferred embodimentsof the invention without placing limitations thereon.

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The invention will be more fully understood by reference to thefollowing drawings which are for illustrative purposes only:

[0032]FIG. 1 is a plan view of an abrasion-resistant matrix according tothe invention shown with a triangular matrix of cords and abrasion beadsretained at each crossing node.

[0033]FIG. 2 is a side view of the abrasion-resistant matrix of FIG. 1shown with optional exterior appearance layer and inner comfort layer.

[0034]FIG. 3 is a side view of the abrasion-resistant matrix of FIG. 2shown with quilted stitching retaining inner and outer layers together.

[0035]FIG. 4 is a front view of an example torso protection garmentconstructed from the abrasion-resistant beaded matrix shown withincluded body armor sections.

[0036]FIG. 5 is a edge view diagram of the abrasion-resistant beadsshown in sliding contact with a pavement surface.

[0037]FIG. 6 is a diagram of the arm of a rider wearing the beadedmatrix, wherein the rider's arm is in sliding contact with the pavement.

[0038]FIG. 7 is a diagram of an alternate trapezoidal beaded matrixaccording to the invention.

[0039]FIG. 8 is a diagram of a series of cords within a triangularmatrix prior to attachment of the abrasion-resistant beads.

[0040]FIG. 9 is a cross section view of a proposed manner of injectionforming the beads over the series of cords within the matrix.

[0041]FIG. 10 is a plan view of a completed bead matrix produced by theinjection process shown in FIG. 9.

[0042]FIG. 11 is a diagram of an alternate embodiment of the beadedmatrix wherein additional span beads are attached between the nodalbeads within the matrix.

[0043]FIG. 12 is a diagram of an alternate embodiment of a non-nodalbeaded matrix configured for a particular frictional direction.

[0044]FIG. 13 is a diagram of an alternate manufacturing method whereinthe cords of the beaded matrix are threaded through a ventilated clothlayer.

[0045]FIG. 14 is a detailed view of an embodiment of abrasion resistantcord showing belts of Kevlar surrounding a central material core whichpreferably contains elastic.

[0046]FIG. 15 is a side view of a portion of the beaded matrix accordingto the invention which is shown utilizing beads of varying sizes.

[0047]FIG. 16 is a cross-section of an abrasion resistant bead accordingto an embodiment of the present invention, shown having an interiorfilled with a light material.

[0048]FIG. 17 is a cross-section of an abrasion resistant bead accordingto an embodiment of the present invention, shown having an exteriorshell configured with expanded cord apertures.

[0049]FIG. 18 is a cross-section of an abrasion resistant bead accordingto an embodiment of the present invention, shown having interiorstructures to improve rigidity.

[0050]FIG. 19 is a front view of an example trouser garment constructedfrom the abrasion-resistant beaded matrix shown with included body armorsections.

[0051]FIG. 20 is a cross-section of a bead according to an aspect of thepresent invention, shown with an insert surrounding the cord entry andexit into the bead.

DETAILED DESCRIPTION OF THE INVENTION

[0052] Referring more specifically to the drawings for illustrativepurposes, the present invention is embodied in the apparatus generallyshown in FIG. 1 through FIG. 20. It will be appreciated that theapparatus may vary as to configuration and as to details of the partswithout departing from the basic concepts as disclosed herein.

[0053] An abrasion-resistant matrix 10 according to the invention isshown in FIG. 1. A series of beads 12 are shown by way of exampleinterconnected in a triangular matrix of cords 14. The beads 12 withinthis embodiment are preferably manufactured from UHMW-PE(ultra-high-molecular-weight polyethylene) which has three times theabrasion resistance of steel while having low surface friction andproviding thermal insulation. Bead size and spacing depend largely onthe location on the garment (i.e. exterior thigh bead size preferablylarger than interior thigh bead size) and the duty required along withthe construction and number of optional layers used with the beadmatrix. By way of example and not of limitation, a bead size isdescribed herein as preferably set for five millimeter (5 mm) indiameter while the corresponding bead to bead spacing is 20 mm.Alternate sizes and spacing can provide for use over various partswithin a garment, duty, and construction. Bead size may be varied sothat material is conserved in areas subject to less risk of abrasion.

[0054] The cords 14 are so constructed to provide high tensile strengthand abrasion resistance, even when directly applied against the abrasivesurface under bead rotation. Numerous materials separately or incombination can provide the needed strength. Materials such as Kevlar™and other Aramid or para-aramid fibers, along with other high tensilematerial such as ballistic nylon, Cordura™, Gortex™ and carbon, boron,basalt, or similar fibers may be incorporated to provide excellentstrength and durability.

[0055] The cords 14 are preferably constructed to provide limitedelasticity so that the garment will fit securely during high speedriding. Threads, or bands, of Kevlar™ or other high abrasion-resistantmaterial, can be knitted to form a cord exhibiting limited elasticstretching. Alternately, bands/threads of Kevlar™, or graphite fiber,can be wrapped or woven with another cord or set of knitted or twistedthreads. The cord as currently embodied is preferably at least 1.0 mm indiameter.

[0056] Although smaller diameters can provide adequate strength, theymay uncomfortably dig into the skin under high compressive or rotationalbead loading which tightens the cord matrix against the skin. It must beunderstood that other cord compositions may be utilized which will beobvious to one skilled in the art, preferable are those which providefor limited elastic stretching along with high tensile and abrasiveresistance. One preferred method for increasing the diameter of thecords without increasing strength above a reasonable tear-awaythreshold, is to sheath the cord in an abrasion resistant material whichpreferably operates in concert with an elastic cord wrapped about thecord to allow it to stretch slightly to improve fit.

[0057] The preferred range of tensile strengths for the cords is in therange of from 25-250 lbs. The use of lower tensile strength cords, suchas in the low range above or below, being generally predicated onallowing cords in the suit to tear-away instead of imposing high loadsonto the wearer. If tear-away cords are utilized then rip stopmechanisms, such as locked cord nodes, and the like should be utilizedto limit the extent to which the material may tear under load.

[0058] The representative abrasion resistant beaded matrix shown in FIG.1 can be directly tailored into a garment that preferably includesimpact protection at strategic locations. It is anticipated that ingeneral, the beaded matrix will be implemented within additional layersto enhance both comfort and visual appeal. FIG. 2 shows a beaded matrixsandwiched between two layers 30 of cloth. The beads 32 and cords 34 ofthe beaded matrix are held between an outer layer 36 and an inner layer38. Composition of the inner and outer layers depends on the duty withwhich the garment is intended. Although the beaded matrix allows for theconstruction of safety garments with flow-through ventilation that canbe worn comfortably even in the warmest weather, it can also be usedwithin heavy winter weight garments, along with racing suits, motorcrossoutfits, and a wide variety of other abrasion resistant safety garments.For a very light summer weight garment the outer layer 36 preferablycomprises a Cordura™ shell with reinforced ventilation holes. Manyfabrics are manufactured for sports that provide strength andventilation. It will be appreciated that the outer shell need notprovide abrasion resistance because the bead matrix prevents any largeareas of integument from being abraded on the roadway, or other surface.The inner layer 38 may be of a light cotton liner material that providesa soft and absorbent material against the skin of the wearer. To retainthe layers in the proper orientation to one another and to prevent thefabric from flapping in response to air pressure changes, the inner andouter layers are preferably stitched (quilted) to one another as shown50 in FIG. 3 surrounding beads 52 contained on cords 54. Obviously, thestitching between outer layer 56 and inner layer 58 preferably connectsthe two layers between the beads 60 through the corded area 54 so thestitching does not need to pass through the thick material of the beads52.

[0059]FIG. 4 shows an example of a torso protection garment 70constructed from the abrasion-resistant beaded matrix 72 shown withincluded body armor sections. The garment is shown for clarity withoutan outer fabric shell while the cord connecting the beads is not visiblein this overall view. It is preferable for such a garment to include anumber of additional safety features. Elbow armor 74 a, 74 b, andshoulder armor 76 a, 76 b, preferably provide hard abrasion-resistantexterior shells with dense foam shock absorbing liner material. Thecords of the beaded matrix, sans beads, are preferably sandwiched withinthe armor pads to assure that the armor is unable to separate from thecord matrix and thereby the remainder of the garment. Alternatively, thematrix of cords may be sewn into or around the armor sections forretaining the garment and armor in place. The ends of the garmentterminating at the wrists 78 a, 78 b is preferably reinforced andprovided with a closure, such as a snap, so that the sleeve is retainedover the forearm. During a slide the forearm may contact the ground suchthat the contact friction attempts to pull the sleeve portion of thegarment away from the wrist. It is preferable therefore that the sleevebe retained so that the wrist area does not become exposed to abrasion.A fastener, such as a snap, can be used to narrow the opening at thewrist after the hand has been inserted into the garment; the restrictedopening thereby prevents the sleeve from substantial movement. Otheralternative means of retaining the sleeve include attachment to a glove,and the use of finger webbing, whereby one or more straps wrap aroundbetween the fingers of the hands. An underlining region 80 is providedto retain the torso garment from shifting around the midsection. If thebottom of the torso garment is not retained in some manner then thebeaded matrix may shift under sliding force to expose large areas of theskin. The torso garment 70 is preferably attached to a full lengthtrouser garment that contains an abrasion resistant beaded matrix andarmor sections. The neck 82 of the garment is reinforced and may beequipped with snaps to prevent gaps around the neck area. A garment maybe alternatively fabricated in a coverall style so that the interfacebetween an upper and lower portion does not exist.

[0060] In use, this beaded matrix offers a unique mode of protecting thewearer. Referring now to FIG. 5 a series of beads 90 are shown underabrasive contact with an asphalt surface. For clarity, FIG. 5 shows arow of beads in isolation without coverings, other beads or bodyportions. The skin of the wearer is held above the pavement riding on abeaded surface. Between the beads 92 a through 92 c are gaps where noprotective material may exist. However, the wearers skin does notcontact the asphalt surface 96 due to the matrix of cords 94 a through94 d which retain the skin above the pavement surface. Furthermore,under the sliding friction the beads tend to rotate to cause the cordmatrix to tighten within that area of the garment to more securelyretain the body area off of the pavement. During a very short intervalas a result of an initial high-G impact it may be possible for smallportions of the skin to make incidental contact with the ground throughthe openings in the matrix, but as the force translates to a slidingforce then only the weight of the rider should then be held above thebeads during the slide. Should such incidental contact occur it wouldnot result in significant injury. It is preferable that a limitedstretch fabric be used within an optional lining to provide comfort andto prevent even incidental contact as it provides a trampoline effectbetween the beads in the matrix. The underside of each bead 92 a through92 c can be easily seen in this view to proffer a smooth surface at theinterface with the pavement 96. Smooth transitions with the pavementreduce the chances of the material “catching” the ground. When amaterial under abrasive sliding contact catches the ground, the forceson the garment drastically increase at that location, since the entiremomentum of the rider may be temporarily caught at that one point,whereby the chances of tearing the garment increase and rotationaltorque forces applied to the sliding body can increase dramaticallyleading to increase risk of fractures.

[0061]FIG. 6 is a diagram of a rider's arm within the beaded matrix 110shown in sliding contact with a pavement surface 118. Upper arm 112 andforearm 114 are covered with the abrasive resistant beaded matrixaccording to the invention while the rider's hand is covered with aglove 116. Protecting the bone of the elbow is shown an armor cup 120that has a rigid abrasive-resistant exterior and a firmly paddedinterior. In this view, a row of beads 122 a through 122 g can be seenin contact with the pavement surface. As the rider slides they areretained above this platform of abrasive-resistant, but low frictionbeads. The force of the slide is dissipated within the beads and not thearm of the rider.

[0062] The cord matrix of the invention may be configured in a varietyof structures and geometric configurations, such as triangular, square,hexagonal, octagonal, and so forth, depending upon the area of intendeduse and the application. FIG. 7 is an alternate trapezoidal beadedmatrix 130 according to the invention, shown with beads 132,longitudinal cords 134, and vertical cords 136.

[0063] The abrasion resistant garment employing the beaded matrix of theinvention can be manufactured in a variety of ways. Individual beads maybe integrated, or assembled within the corded matrix, or molded onto acord matrix as described by FIG. 8 through FIG. 10 which shows a moldingprocess of manufacture. In FIG. 8 a set of high-tensile strengthabrasive resistant cords 150 are held in a web configuration betweenwhich triangular spaces exist. Cords within a first cord direction 152,a second cord direction 154, and a third cord direction 156 are retainedwith cross over points 160. A cross-section of the matrix is shown onedge in FIG. 9 with an injection bead molding apparatus 170, closingdown on the cord matrix, with bead molds, such as 172 being shownalongside a mating surface 174. The mating surface 174 can attain securecontact with the mating surface 184 of the opposing side of the mold 188while leaving small necked down channels the cords to pass undamagedbetween the injection mold heads 178 and 188. Injection sites withineach bead mold are fed by a series of passageways 176, 186 through whichthe molten plastic material may be injected into the closed mold at thesite of each bead. The resultant abrasion resistant beaded matrixaccording to one embodiment of the invention is shown in FIG. 10. Cordswith first 152, second 154, and third 156 directions are attached to oneanother within each rounded bead 160.

[0064] An alternate embodiment of the abrasion resistant beaded matrixstructure is shown in FIG. 11. The beaded matrix herein contains cordingattached at nodes 212, wherein the cording is in a first 214, second216, and third 218 direction. Additional span beads 220 are attachedbetween the nodal beads 212 within the matrix. Such arrangement,however, is generally less preferred than the use of spherical beads.

[0065] An alternate embodiment 230 configured for a particular directionof sliding is shown in FIG. 12. This form of beaded matrix is anon-nodal beaded matrix wherein the beads are all contained on the spancords between nodes. This matrix requires that the cords be retained toone another by a bonding means which may comprise thermal bonding,tying, a material envelope, or adhesives. Again, this is generally lesspreferred in the majority of applications in relation to the array ofspherical beads.

[0066]FIG. 13 shows an alternative method of manufacturing theabrasion-resistant beaded matrix 250 of the invention. Beads 252 athrough 252 d are attached to one another by means of theabrasion-resistant cords 254, which are also threaded through one ormore layers of material. The cord 254 is shown entering a bead 252 d atentry 258 through the width of the bead by tube 260. An aperture 262 isan opening for a cord retaining the bead in the opposing orientation.Again, within this embodiment, rotation of the beads of the matrixduring a slide, create constrictive forces on the cord matrix to retainthe skin of the wearer off of the surface of the road. In the priorembodiments the beads were molded onto the nodes of the cord matrixwhich prevented them from moving along one or more respective cord.Within this embodiment, the beads are retained from sliding movement bythe fabric attachment through which the cord passes. To prevent fabricfailure that could allow bead movement, it is preferred that the fabricemployed within this embodiment be a perforated cloth containingperiodic high-tensile strength abrasion resistant fibers. Additionalinner and outer layers of material may be attached to the beaded matrix250 as in the other embodiments described.

[0067]FIG. 14 exemplifies a single cord of material 270 for use withinthe corded matrix, and comprises a central core 272 which preferably hasa high strength fibrous material into which is incorporated elasticstrands, and exterior high-abrasion resistant strands of material, suchas Kevlar™, to prevent the cord from wearing through during an abrasiveincident.

[0068] Referring to FIG. 15 is shown a portion of a beaded matrix 275,wherein the cord matrix 276 retains beads 277, 278, and 279 which arevariously sized according to the area of application about the exteriorof the body. It will be appreciated that areas of low abrasion risk maybe spanned by the cord matrix which is configured without beads.

[0069] Referring now to FIG. 16 through FIG. 18, it will be appreciatedthat the beads within the matrix may be manufactured in numerousconfigurations, so long as the bead provides an abrasion resistantexterior. FIG. 16 is a beaded matrix portion 280, having a bead 282 on acord 284 passing though the bead at openings 286. The bead 282 in thisexample is filled with a light weight material 288 capable of enhancingcord retention within the bead shell. FIG. 17 is a beaded matrix portion290 having a bead 292 on a cord 294, wherein openings 296 within bead292 are configured with rounded edge expanded cord apertures 298 whilethe interior of bead 292 is hollow. The use of rounded edges at theinterface between the cord and bead is generally preferred for all beadconfigurations, as acute edges of the bead at the interface mayotherwise abrade the cord proximal the interface. However, theintroduction of the rounded edges may complicate manufacture, whereby alarger cord diameter with additional abrasion resisted may be opted for.FIG. 18 is a beaded matrix portion 300 wherein a bead 302 is attached toa cord fiber 304 and has openings 306. The bead 302 contains interiorstructures 308 a, 308 b for increasing the exterior rigidity of bead302.

[0070] Referring finally to FIG. 19 is exemplified a completed trousergarment 310 which incorporates an embodiment of the beaded matrixaccording to the invention. The trouser has a waistband 312 from whichleg portions 314 extend. The waistband comprises a horizontal loop ofmaterial 316 secured in a closed position by a fastener 318. Theportions of the leg 314 are covered by a combination of beaded matrix320 upon which are attached impact resistant body armor at strategiclocations, such as at sections 322 (over the hip bone) and 324 (over theknee joint) as shown. The lower portion of the garment terminating atthe ankle is configured with a band 326 which is securely retained in aclosed position by a fastener 328, such that the material matrix may notegress from the ankle area upon the application of force during sliding.It will be further appreciated that the beaded matrix of the presentinvention may be utilized over more limited regions within a garment asto provide for air-flow without the loss of abrasion resistance.

[0071]FIG. 20 depicts an aspect of beads 350 according to the presentinvention, in which a compliant material is retained within the entryand exit points for the cord within the beads. The cords of the matrixpass through the compliant material as it exits the bead to distributethe forces and reduce the chance of cord being cut by the material ofthe bead. The compliant material may comprise a plastic, silicon, latex,or other material that preferably has properties similar to rubber.

[0072] A bead 352 is shown having cord entry exit shaped 354 forretaining a compliant material 356, which can not readily be separatedas a consequence of the retention area 358, shown as a constrictedportion of bead 352. A cord 360 is shown passing through the compliantmaterial and connecting to a crossing cord 362 in the middle of bead352. It should be appreciated that the entry, exit materials may beutilized in combination with any desired forms of bead construction.

[0073] For molded on beads the liner material is preferably first moldedonto the matrix such as at a given radius from each crossing (node) ofthe matrix. The material should be shaped so that it will not easilyseparate from the bead. The following figure depicts a shape thatprovides a smooth transition for the cord at the exit, preventing excessdamage, and prevents easy separation of the soft material. The external“knobs” of material also prevent the cord from being abraded at the exituntil the material is worn through.

[0074] Although the description above contains many specificities, theseshould not be construed as limiting the scope of the invention but asmerely providing illustrations of some of the presently preferredembodiments of this invention. Thus the scope of this invention shouldbe determined by the appended claims and their legal equivalents.Therefore, it will be appreciated that the scope of the presentinvention fully encompasses other embodiments which may become obviousto those skilled in the art, and that the scope of the present inventionis accordingly to be limited by nothing other than the appended claims,in which reference to an element in the singular is not intended to mean“one and only one” unless explicitly so stated, but rather “one ormore.” All structural, chemical, and functional equivalents to theelements of the above-described preferred embodiment that are known tothose of ordinary skill in the art are expressly incorporated herein byreference and are intended to be encompassed by the present claims.Moreover, it is not necessary for a device or method to address each andevery problem sought to be solved by the present invention, for it to beencompassed by the present claims. Furthermore, no element, component,or method step in the present disclosure is intended to be dedicated tothe public regardless of whether the element, component, or method stepis explicitly recited in the claims. No claim element herein is to beconstrued under the provisions of 35 U.S.C. 112, sixth paragraph, unlessthe element is expressly recited using the phrase “means for.”

What is claimed is:
 1. An abrasion resistant material for use inprotective clothing, comprising: (a) a plurality of beads having roundexteriors; and (b) a matrix of cords interconnecting said plurality ofbeads in a two dimensional pattern toward providing high abrasionresistance.
 2. An abrasion resistant material as recited in claim 1,wherein said attachment occurs substantially through the center of eachof said beads.
 3. An abrasion resistant material as recited in claim 1,wherein the exterior of the bead comprises UHMW polyethylene.
 4. Agarment material for use within abrasion resistant clothing, comprising:a plurality of beads of an abrasion resistant material having roundedexteriors; and a matrix of cords interconnecting said beads andconfigured for retaining said beads in a fixed two-dimensional patternas a material from which abrasion resistant clothing may be fabricated.5. A garment material as recited in claim 4, wherein said matrix ofcords comprise material of sufficiently high tensile strength to preventsaid beads from disconnecting from said matrix of cords in response tosliding contact with a roadway surface.
 6. A garment material as recitedin claim 4, wherein said matrix of cords are attached to said pluralityof beads through a material portion of each of said beads.
 7. A garmentmaterial as recited in claim 4, wherein at least the exterior portionsof said beads comprise an abrasion resistant material having acoefficient of friction sufficiently low as to reduce inducingrotational torque forces on a wearer of said garment in response tosliding contact with a roadway surface that can lead to additionaltumbling injuries.
 8. A garment material as recited in claim 4, furthercomprising compliant material inserts retained where said cord entersthe material of said bead.